Alfalaval Unique Single Seat Valve User manual

Instruction Manual
Unique Single Seat Valve - ATEX Standard
TD 474-001
ESE00674-EN3 2011-05
Original manual

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 8
3.1. Unpacking/delivery ............................................................................... 8
3.2. General installation ................................................................................ 10
3.3. Welding ............................................................................................ 11
3.4. Recycling information ............................................................................. 12
4. Operation ............................................................................................... 13
4.1. Operation .......................................................................................... 13
4.2. Troubleshooting ................................................................................... 15
4.3. Recommended cleaning ......................................................................... 16
5. Maintenance ........................................................................................... 18
5.1. General maintenance ............................................................................. 18
5.2. Dismantling of valve .............................................................................. 20
5.3. Plug seal replacement ............................................................................ 21
5.4. Assembly of valve ................................................................................. 21
5.5. Actuator bushing replacement .................................................................. 22
5.6. Dismantling of optional maintainable actuator ................................................. 22
5.7. Use ................................................................................................. 22
5.8. Additional equipment ............................................................................. 23
6. Technical data ......................................................................................... 24
6.1. Technical data ..................................................................................... 24
7. Parts list and Service Kits ........................................................................... 26
7.1. Drawing ............................................................................................ 26
7.2. Unique Single Seat Valve ......................................................................... 27
7.3. Drawing ............................................................................................ 32
7.4. Unique Single Seat Valve - Reverse Acting .................................................... 33
7.5. Maintainable actuator ............................................................................ 37
3

1 EC Declaration of Conformity
The designating company
Alfa Laval
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Unique Single Seat Valve Standard and Reverse Acting
Denomination Type Year
is in conformity with the following directives:
- Machinery Directive 2006/42/EC
- Pressure Equipment Directive 97/23/EC category 1 and subjected to assessment procedure Module A.
Manager, Product Centres, Compact
Heat Exchangers & Fluid Handling
Bjarne Søndergaard
Title Name
Alfa Laval Kolding
Company Signature
Designation
4

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
2.1 Important information
Always read the manual before using the valve!
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the valve.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Caustic agents:
5

2Safety
All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury and/or damage to the valve are avoided.
2.3 Safety precautions
Installation
Always read the technical data thoroughly.
Always release compressed air after use.
Never touch the moving parts if the actuator is supplied with compressed air.
Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
Never dismantle the valve with valve and pipelines under pressure.
Never dismantle the valve when it is hot.
Operation
Never dismantle the valve with valve and pipelines under pressure.
Never dismantlethevalvewhenitishot.
Always read the technical data thoroughly.
Always release compressed air after use.
Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
Never touch the moving parts if the actuator is supplied with compressed air.
Always rinse well with clean water after the cleaning.
Beware of min./max. temperatures.
Always handle lye and acid with great care.
Maintenance
ATEX Version only by use of genuine Alfa Laval parts.
Never replace ATEX actuator with other type of Alfa Laval actuators.
Spareparts: see also Parts Lists and Service Kits. Chapter 7.
Always read the technical data thoroughly.
Always release compressed air after use.
Never service the valve when it is hot.
Never service the valve with valve and pipelines under pressure.
Never stick your fingers through the valve ports if the actuator is supplied with compressed air.
Never touch the moving parts if the actuator is supplied with compressed air.
6

2 Safety
All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury and/or damage to the valve are avoided.
Transportation:
Always secure that compressed air is released
Always secure that all connections is disconnected before attemt to remove the valve from the installation
Always drain liquid out of valves before transportation
Always used predesigned lifting points if defined
Always secure sufficient fixing of the valve during transportation - if special designed packaging material is available it must
be used
7

3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The items refer to parts list and service kits section.
The valve is supplied as separate parts as standard (for welding).
The valve is assembled before delivery, if it is supplied with fittings.
3.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve, shut off valve (RA) or change-over
valve(RA)(seesteps2a,2b,2cand2d).
2. Delivery note.
Step 2
2a
Shut-off valve:
1. Complete actuator.
2. Bonnet (20).
3. Clamp (19).
4. Valve plug (23).
5. Valve body (22).
6. Ground wire (64).
TD 461-943
64
2b
Change-over valve:
1. Complete actuator.
2. Bonnet (20).
3. 2 x clamp (19).
4. Valve plug (27).
5. Lower valve body (22).
6. Valve seat (28).
7. Upper valve body (26).
8. Ground wire (64).
TD 461-944_1
64
UP
2c
Shut-off valve - Reverse Acting:
1. Complete actuator.
2. Bonnet (20).
3. 3 x clamp (19).
4. Valve plug (23).
5. 2 x upper valve body (26).
6. Valve seat (28).
7. Lower bonnet (33).
8. Ground wire (64).
TD 461-945_1
64
UP
8

3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The items refer to parts list and service kits section.
The valve is supplied as separate parts as standard (for welding).
The valve is assembled before delivery, if it is supplied with fittings.
2d
Change-over valve - Reverse Acting:
1. Complete actuator.
2. Bonnet (20).
3. 4 x clamp (19).
4. Upper valve plug (34).
5. Lower valve plug (35).
6. 3 x upper valve body (26).
7. 2 x valve seat (28).
8. Lower bonnet (33).
9. Ground wire (64).
TD 461-946_1
64
UP
Step 3
Remove possible packing materials from the valve/valve parts.
9

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has welding ends as standard but can also be supplied with fittings.
3.2 General installation
Step 1
Always read the technical data thoroughly.
See chapter
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
Step 2
Never touch the moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
TD 461-006_01
Step 3
It is recommended to install the valve so that the flow is against
the closing direction to avoid water hammer.
Shock in the actuator must never occur.
Avoid water
hammering!
Inlet
TD 461-947
Inlet
Step 4
Avoid stressing the valve.
Pay special attention to:
-Vibrations.
- Thermal expansion of the pipelines.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage!
TD 461-948
10